The Loader s Guide to Truck Loading Everal Lane Franklin, TN / (fax) info@warehouseoptimization.

Transcription

1 The Loader s Guide to Truck Loading 4650 Everal Lane Franklin, TN / (fax) info@warehouseoptimization.com

2 To be a good truck loader, you need to keep a lot of people happy Keep it legal What I ordered, easy to count and unload and is undamaged Balance the load and don t let it move around Load it fast and damage free Page 1

3 Making loads that please everyone is hard Must be satisfied Nice to satisfy these guys Page 2

4 The Highway Patrol wants the trucks to be legal Axle Weight Axle Weight Axle Weight Keep axles below 34,000 pounds 34,000 34,000 80,000 12,000 Keep axles spaced far apart 48 ft...and the load must be stable Page 3

5 Loads to certain states e.g. CA. need to be have unique trailer set-ups In some states the laws are different Axle Weight Axle Weight Axle Weight 34,000 34,000 12,000 Axle spacing is limited E.g. California limits how far the axles can be apart. so you need to load differently Page 4

6 Getting the axle weights right is hard Here are some rules I use. They work most of the time Light / Heavy / Light No more than 2000 pounds per floor spot Single/Double/Single Page 5

7 Loading a trailer is like working a seesaw We all understand a seesaw And a trailer is like that Page 6

8 ..but it gets tough--and I need help Distance from center of tandems To calculate the weight on the axles and king pin requires a lot of calculations. I can t do them in my head! So when loads get heavy (40,000 pounds and above), I ask for help Center Of Gravity King Pin Page 7

9 Customers want what they want, when they want it Where do I put this? Get all the order on the truck And Make it easy to count Page 8

10 Customers want what they want, when they want it 1st stop 2nd stop Last stop In the right stop sequence And try to keep the orders together If keeping orders together makes a load infeasible or creates other problems, then allow the orders to be mixed in the stop. Order #3 Order #2 Order #1 Page 9

11 Easy to unload How can a customer unload this pallet with a pallet jack? Another customer s order Page 10

12 Easy to unload and load SOAP PAPER PAPER BEAUTY CARE HEALTH CARE SOAP SOAP Try to keep product families together And some of my sites have small dock doors-- so make sure we can unload it If the customer has small doors, make sure that last pallets go On in the narrow direction. Page 11

13 The Boss wants high productivity and no damage What do I do first? Bring multiple pallets at the same Time and don t waste time thinking Page 12

14 Easy to load: based on how the product is stored in the warehouse Narrow/Narrow Chimney Block Wide/Wide If pallets of product are stored in the narrow direction, this is the easiest If pallets of product are stored in the wide direction, this is the easiest Page 13

15 Minimize warehouse travel D C B A D/A Better D C B A B/A Page 14

16 Make products easy to retrieve and touch in the trailer (Same items on top of one another and same families in each grab) Top View Side View B/B A/A A/A B A A B/B A/A A/A B A A B/B B/B A/A B A A B/B A/B A/A B B A B/B A/A A/A B B A B/B B/B A/A B B A Goal: Support picking up product in double-wide fork trucks. Page 15

17 Make products easy to retrieve Prefer C s together E/C C/D A/A F/C D/D B/B Vs. E/C C/C A/A F/D D/D B/B If possible, on the bottom is preferred C/E C/C A/A F/D D/D B/B When you do this, you need to Make sure you obey the other rules, like don t double stack Page 16

18 and don t damage anything, because we have to pay for it But what causes damage? Page 17

19 Things that might stack nicely in the warehouse get damaged bumping along the road It may look fine when it leaves the dock But, if it is not built right, the customer sees a very different load when it arrives Page 18

20 Put strong items on the bottom of stacks Check to see if product is: fikept apart from others fialways on the bottom or top fistrong enough to carry other unit loads B A B C Page 19

21 Damage is also caused by pallet movement or falling Try to brace forward, backwards and to the side so pallets cant move Page 20

22 Small pallets should not be alone on the floor - make all stacks exceed some minimum height 26 Don t put short pallets on the floor Page 21

23 Special loading for TOFC / intermodal / containers Be more careful with TOFC Over-the-Road TOFC Good Requires 2-3 airbags Good Better, but still needs airbags Page 22

24 When bracing, keep singles or unit loads with product severely under-hanging the pallet in non-critical position Turn pallets at critical points wide / Wide so the airbag fits tighter -- But you can t do that when the Customer has small docks Critical points Try not to have singles in a load and definitely not consecutive singles Page 23

25 To minimize damage, minimize the height differential between adjacent pallets and number of consecutive singles Undesirable Better Best Too short Undesirable Better Single No singles in the nose or tail Page 24

26 Low density product, turn pallets to max-out the trailer to back door A big gap here will generate damage If the product is light (like paper) turn some pallets to minimize the gap in the back Page 25

27 Minimize side movement Minimize stack height differential Minimize how often this occurs. Try to never have this in the last spot in the trailer. Double stretch wrap and turn pallets near such a stack Page 26

28 Use dunnage where there are significant areas of unbraced pallets Turn pallets wide at the middle and back of the trailer where you airbag Airbag Airbag Airbag where there are significant changes in height Airbag back - always Airbag -- for long trips or TOFC..and make the stacks in the back tall Page 27

29 Use fillers when the product significantly under-hangs the pallet Use cardboard fillers Where there is more than 2 of pallet showing and don t use airbags when the gap is more than 10 inches Filler 2 + Filler goes against the wall Page 28

30 Certain product needs special rules You have to learn which products must: firide on top fialways be on the bottom finot be turned wide wide (they overhang the pallet too much) fimust be kept separate Page 29

31 You may need to save space for out-of-stock items at back of trailer OK Phantom pallet Best Stack product Page 30

32 What is more important? I know you can t keep all the rules all the time. Here is what I think is most important: 1. Make the axles legal 2. Keep stops separate 3. Brace forward 4. Brace sideways, particularly on second level 5. Keep orders separate (if you can) 6. Turn last 2 pallets (if you can) 7. Meet desired customer loading pattern 8. Keep same items together 9. Brace backwards 10. Keep families together Page 31

33 What they tell you but it s not true Load short & then tall to get the maximum weight in a trailer Airbag Airbag Wile this works, it requires more airbags Airbag Vs. Airbag Page 32

34 What they tell you but it s not true Only load to 48 ft. in a 53 ft. trailer. 48 ft. As long as you can keep the axles Legal, don t worry about the Stupid line Page 33

35 Remember, it is hard to load a truck well When loading a truck, there is a lot to remember -- and a lot of decisions to make. Some companies even have sophisticated software from Warehouse Optimization to help make loading faster and allow getting more product on the trailer Page 34

36 We wish you success This document was developed based on interview with loaders by: Warehouse Optimization 4650 Everal Lane Franklin, TN / You are welcome to use it -- but we accept no liability. Address any questions or comments to: Page 35